Tag: tuning

Volvo S80 2.4T Plastidipped Grill

I wanted a cleaner look for the front grill and decided to use plastidip instead of the carbon wrap. It came out great and suits the black S80 very well.

I used Motip Removable Coating instead of classic Plastidip and it holds very well till this day.

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Also repainted the front trim with bumperspray (which didn’t hold by the way).

Volvo S80 2.4T Repainted Trim


Volvo S80 2.4T Custom Exhaust

When fitting the 3″ BSR downpipe, I needed a new exhaust. As a temporary solution, I bought a standard exhaust kit (resonator and backbox) and modified the midpipe (cut the resonator out). It sounds quite nice for a default exhaust, but cannot beat a stainless exhaust 🙂

Volvo S80 2.4T Old vs New Backbox

Volvo S80 2.4T Old vs New Backbox

Volvo S80 2.4T Old vs New Modified Exhaust

Volvo S80 2.4T New Catback

Volvo S80 2.4T New Catback

Volvo S80 2.4T BSR 3" Downpipe + New Catback

Volvo S80 2.4T Modified Center Silencer

Volvo S80 2.4T Modified Center Silencer

Volvo S80 2.4T Modified Center Silencer

Volvo S80 2.4T Modified Center Silencer


Volvo S80 2.4T BSR Tuning 3″ Downpipe

To upgrade the performance on any turbo powered car, you need “breating” upgrades. The car needs to inhale better (intake modifications), but also exhale better (exhaust modifications).

The most important component in the exhale process is the downpipe, the first pipe after the turbo. Upgrading this to a larger diameter, will allow for quicker turbo spool, which helps in scavenging but also in building boost.

As a pleasant side effect, the exhaust note will also be more throaty! The S80 has very limited options on paper, but I was able to buy and fit this with help from J&D Auto Onderdelen, who helped me tremendously in the pre-sales process (making sure that everything would fit). I can highly recommend them!

It’s a quite expensive upgrade, but well worth it.

BSR 3" Downpipe with Sports Catalyst

BSR 3" Downpipe with Sports Catalyst

BSR 3" Downpipe with Sports Catalyst

BSR 3" Downpipe with Sports Catalyst

Volvo S80 2.4T 3" BSR Downpipe (Inside view)

It’s highly recommended to get some new nuts for securing the downpipe.

Volvo S80 2.4T Genuine Parts (Locking Nuts)

Old vs new, look into the differences in the diameter of the neck.

Volvo S80 2.4T 3" BSR Downpipe

Volvo S80 2.4T BSR 3" Downpipe + New Catback

Volvo S80 2.4T BSR 3" Downpipe + New Catback


Volvo S80 2.4T Project 16T Turbo

I had pretty big plans for the S80, shooting for a 270bhp instead of the 200bhp that the 2.4T has normally. You need an upgrade turbo for this, which I sourced from a T5 model, which has 250bhp bone stock. The swap would involve the TD04HL-13T to TD04HL-16T or 13T to 16T for short.

Fitment is pretty straightforward, but the coolant lines run differently, and this was quite a hassle as information on the internet seems very scarce. I found some, but needed some creativity as the build progressed.

I was also planning to mount the later “R” series manifold, but decided to sell it, as the Japanifold would give much better sound and equal performance.

In the end, I sold the 16T and mounted the 13T, saving the money up for something else. I needed to adjust the car a little bit, and according to the max MAF values, it makes about 240-245bhp, which is awesome.

It’s a totally different car from when I first bought it, that’s for sure!

Volvo S80 2.4t TD04HL-16T Turbo

Volvo S80 2.4t TD04HL-16T Turbo

The TD04HL-16T with the R-manifold

Volvo S80 2.4T TD04HL-16T + Upgrade Exhaust Manifold

The TD04HL-13T vs TD04HL-16T

Volvo S80 2.4T TD04HL-16T vs 13T turbo

Volvo S80 2.4T TD04HL-16T vs 13T turbo

Volvo S80 2.4T TD04HL-16T vs 13T turbo

Modifications needed for fitting the coolant lines

Volvo S80 2.4T Coolant Line Modification

Volvo S80 2.4T Coolant Line Modification

Rubbing will occur here

Volvo S80 2.4T Coolant Line Modification


Volvo S80 2.4T Diffuser

Added 2 diffusers to the rear bumper of the S80. Looks very nice and makes the S80 less of a Old Man car haha 🙂

URL: https://www.aliexpress.com/item/32853258621.html

Volvo S80 2.4T Diffuser

Volvo S80 2.4T Diffuser